MacDon R216 User manual

R216
Rotary Disc Header
Operator’s Manual
215026 Revision A
Original Instruction
The harvesting specialists.

R216 Rotary Disc Header
1030661
Published October 2019.
© 2019 MacDon Industries, Ltd.
The information in this publication is based on the information available and in effect at the time of printing. MacDon
Industries, Ltd. makes no representation or warranty of any kind, whether expressed or implied, with respect to the
information in this publication. MacDon Industries, Ltd. reserves the right to make changes at any time without notice.
Noise Levels
The A-weighted sound pressure level inside the operator’s station of a typical self-propelled vehicle (e.g., M1240), when
operated in conjunction with this R216 Rotary Disc Header, is 70 dBA. This measurement was taken in accordance with ISO
5131. The sound pressure level depends upon the rotary disc speed, crop conditions, as well as the exact type of self-
propelled vehicle used to power the R216 Rotary Disc Header.

Introduction
This instructional manual contains safety, operating, and maintenance procedures for the MacDon R216 Rotary Disc
Header. The rotary disc header when attached to a MacDon M1240 Windrower, is designed to cut, condition, and lay a
wide variety of grasses and hay crops in windrows.
Carefully read all the material provided before attempting to unload, assemble, or use the machine.
Use this manual as your first source of information about the machine. If you follow the instructions provided in this
manual, and use MacDon parts, the rotary disc header will work well for many years. If you require more detailed service
information, contact your Dealer.
Use the Table of Contents and the Index to guide you to specific topics. Study the Table of Contents to familiarize yourself
with how the material is organized. Keep this manual handy for frequent reference and to pass on to new Operators or
Owners. Call your Dealer if you need assistance, information, or additional copies of this manual.
When setting up the machine or making adjustments, review and follow the recommended machine settings in all relevant
MacDon publications. Failure to do so may compromise machine function and machine life and may result in a hazardous
situation.
MacDon provides warranty for Customers who operate and maintain their equipment as described in this manual. A copy
of the MacDon Industries Limited Warranty Policy, which explains this warranty, should have been provided to you by your
Dealer. Damage resulting from any of the following conditions will void the warranty:
•Accident
•Misuse
•Abuse
•Improper maintenance or neglect
•Abnormal or extraordinary use of the machine
•Failure to use the machine, equipment, component, or part in accordance with the manufacturer’s instructions
Conventions
The following conventions are used in this document:
•Right and left are determined from the operator’s position. The front of the rotary disc header faces the crop.
•Unless otherwise noted, use the standard torque values provided in this manual.
1028900
A
Manual Storage Case
Store the operator’s manual and the parts catalog in the plastic
manual case (A) on the left fixed deflector.
NOTE: Keep your MacDon publications up-to-date. The most
current version can be downloaded from our website
www.macdon.com or from our Dealer-only site
(https://portal.macdon.com) (login required).
215026 iRevision A

Summary of Changes
At MacDon, we’re continuously making improvements, and occasionally these improvements affect product
documentation. The following list provides an account of major changes from the previous version of this document.
Section Summary of Change Internal Use Only
Inside front cover Added copyright statement. Tech Pubs
Introduction, page i Added note about dealer portal access. Tech Pubs
Summary of Changes, page ii Added list of changes page. Tech Pubs
1.8 Locating Safety Decals, page 9 Changed in safety decals and location. UECN 31081
1.9 Understanding Safety Signs, page 11 Changed in safety decals and location. UECN 31081
2.1 Specifications, page 13 Added feeding elements section. Engineering
2.1 Specifications, page 13 Disc speed changed to 2650 rpm. Engineering
2.1 Specifications, page 13 Added poly roll option. ECN 58790
3.2.1 Engaging and Disengaging Header
Safety Props –M1240 Windrower, page 20
Revised step. Tech Pubs
3.3.1 Installing Forming Shield, page 22 Added topic. Service Dept
3.3.2 Attaching Header to M1240
Windrower, page 24
Revised topic. Service Dept
3.3.3 Connecting R216 SP Hydraulics and
Electrical to an M1240 Windrower, page 29
Replaced the following topics:
•Connecting Disc Header Hydraulics Using
Hard Plumbing –M1240 Windrowers
•Connecting Disc Header Hydraulics Using
Quick Couplers –M1240 Windrowers
Tech Pubs
3.3.3 Connecting R216 SP Hydraulics and
Electrical to an M1240 Windrower, page 29
Revised note. Engineering
3.4.1 Detaching R216 Rotary Disc Header
from M1240 Windrower, page 36
Revised topic.
3.4.2 Removing Forming Shield, page 40 Added topic. Service Dept
Adjusting Skid Shoe Height, page 48 Added topic. Service Dept
Adjusting Gauge Roller Height, page 49 Added topic. Service Dept
3.7.4 Ground Speed, page 53 Revised call out on illustration. Service Dept.
3.8 Conditioner, page 54 Added polyurethane roll information. ECN 58790
3.8.1 Roll Gap, page 54 Added polyurethane roll information ECN 58790
Adjusting Roll Tension, page 56 Added polyurethane roll information. ECN 58790
Adjusting Roll Gap –Polyurethane Rolls,
page 55
Added topic. Tech Pubs
Adjusting Roll Timing, page 57 Revised illustrations to correct driveline
phasing.
ECN 58852
Adjusting Roll Timing, page 57 Revised Steps 11 to 13. Service Dept.
215026 ii Revision A

Section Summary of Change Internal Use Only
Positioning Forming Shield Side Deflectors –
Roll Conditioner, page 61
Removed Step 2. Engineering
3.9 Cutterbar Deflectors, page 65 Added topic. Tech Pubs
3.9.1 Removing Cutterbar Deflectors, page
65
Added topic. Tech Pubs
3.9.2 Installing Cutterbar Deflectors, page 66 Added topic. Tech Pubs
4.4.1 Maintenance Schedule/Record, page
76
Deleted footnote and revised change icon to
lubricate icon in the last entry.
Engineering
4.4.2 Break-In Inspections, page 78 Removed the 25 hours converging drum and
roller belt inspection interval.
Service Dept
4.4.2 Break-In Inspections, page 78 Added 25 and 100 hours drive belt inspection
interval.
Engineering
4.5.2 Lubrication Locations, page 81 Changed in feedroll belt from two belts to
three belts.
ECN 58581
Draining the Cutterbar, page 86 Revised steps. Engineering
Filling Cutterbar with Lubricant, page 87 Added a step on disengaging the windrower lift
cylinder.
Service Dept.
4.6.2 Cutterbar Discs, page 88 Added image. Engineering
Removing Cutterbar Discs, page 90 Added links to removing the outboard cutterbar
discs.
Engineering
Installing Cutterbar Discs, page 92 Added links to installing the outboard cutterbar
discs.
Engineering
Installing Cutterbar Discs, page 92 Removed Step 1 (Installing spacer plate). Tech Pubs
Installing Cutterbar Spindles, page 96 Added illustration and note on using disc
timing tool.
Service Dept
4.6.4 Disc Blades, page 101 Removed information about 11° bevel-down
blades—not for R2 Series.
Service Dept.
Installing Disc Blades, page 107 Added step to remove pin. Service Dept.
Installing Suspended Drums, page 119 Removed step about installing driveline shield. Service Dept.
Replacing Left Suspended Drum Drive Belt,
page 120
Added topic. Service Dept
Replacing Right Suspended Drum Drive Belt,
page 124
Added topic. Service Dept
Removing Left Driven Drum and Driveline,
page 126
New drum shields. ECN 58758
Installing Left Driven Drum and Driveline,
page 129
New drum shields. ECN 58758
Removing Right Driven Drum and Driveline,
page 132
New drum shields. ECN 58758
Installing Right Driven Drum and Driveline,
page 135
New drum shields. ECN 58758
Removing Cutterbar Spindle Shear Pin, page
139
Replaced image to show a sheared shear pin
and added step.
Service Dept
215026 iii Revision A

Section Summary of Change Internal Use Only
Installing Cutterbar Spindle Shear Pin, page
143
Revised procedure. Service Dept
Changing R216 SP Cutterbar Crop Stream
Configuration, page 147
•Revised note re disc timing tool—it is
included with the header.
•Added location of tool on the header.
Service Dept
4.9.2 Removing Cutterbar Curtain, page 156 Revised illustration. Tech Pubs
4.9.2 Removing Cutterbar Curtain, page 156 Revised Step 1. Service Dept.
4.9.3 Installing Cutterbar Curtain, page 157 Added step. Service Dept.
4.10.1 Inspecting Conditioner, page 158 Changed illustrations to show three
feedroll belts.
ECN 58581
4.12.3 Replacing Header Disc Speed Sensor,
page 169
Revised Step 6. Service Dept.
5.1 Cutterbar Deflectors –MD #B6847, page
171
Added topic. Tech Pubs
5.2 Double Windrow Attachment –MD
#C2070, page 172
Added topic. Tech Pubs
5.3 Disc Feed Plate Kit –MD #B6669, page
173
Added topic. Tech Pubs
5.5 Adjustable Gauge Roller Kit –
MD #B6855, page 175
Added information. Service Dept
5.6 Polyurethane Intermeshing Roller –MD
#B6661, page 176
Added topic. ECN 58790
5.7 Steel Intermeshing Roller –MD #B6662,
page 177
Added topic. Tech Pubs
5.8 Adjustable Skid Shoes Kit –MD #B6848,
page 178
Added information. Service Dept
5.8 Adjustable Skid Shoes Kit –MD #B6848,
page 178
Replaced MD #B6667 with MD #B6848. ECN 58703
6.2 Mechanical Problems, page 184 Removed the symptom: Header slows when
going uphill
Engineering
Removed the following topics:
•Changing the Conditioner
•Removing the Conditioner
•Installing the Conditioner
Service Dept. and
Engineering
Recommended Lubricants, inside back cover Revised header drive gearbox oil capacity. Engineering
215026 iv Revision A

Serial Number
Record the serial number and model year of the header in the spaces provided below.
1027799
A
Figure 1: Serial Number Location
Header model: R216 Rotary Disc Header
Serial number:
Model year:
The serial number plate (A) is located on the left side of the
header, on top of the end panel.
215026 vRevision A

215026 vii Revision A
Introduction ................................................................................................................................................i
Summary of Changes....................................................................................................................................ii
Serial Number.............................................................................................................................................v
Chapter 1: Safety ........................................................................................................................................ 1
1.1 Safety Alert Symbols ...............................................................................................................................1
1.2 Signal Words .........................................................................................................................................2
1.3 General Safety .......................................................................................................................................3
1.4 Maintenance Safety ................................................................................................................................5
1.5 Hydraulic Safety .....................................................................................................................................6
1.6 Welding Precaution ................................................................................................................................7
1.7 Safety Signs ...........................................................................................................................................8
1.7.1 Installing Safety Decals....................................................................................................................8
1.8 Locating Safety Decals .............................................................................................................................9
1.9 Understanding Safety Signs .................................................................................................................... 11
Chapter 2: Product Overview................................................................................................................... 13
2.1 Specifications....................................................................................................................................... 13
2.2 Component Identification ...................................................................................................................... 15
2.3 Definitions .......................................................................................................................................... 16
Chapter 3: Operation................................................................................................................................ 19
3.1 Break-In Period .................................................................................................................................... 19
3.2 Engaging and Disengaging Header Safety Props ......................................................................................... 20
3.2.1 Engaging and Disengaging Header Safety Props –M1240 Windrower.................................................... 20
3.3 Attaching Rotary Disc Header to M1240 Windrower ................................................................................... 22
3.3.1 Installing Forming Shield ............................................................................................................... 22
3.3.2 Attaching Header to M1240 Windrower........................................................................................... 24
3.3.3 Connecting R216 SP Hydraulics and Electrical to an M1240 Windrower ................................................. 29
3.4 Detaching Header from Windrower ......................................................................................................... 36
3.4.1 Detaching R216 Rotary Disc Header from M1240 Windrower .............................................................. 36
3.4.2 Removing Forming Shield .............................................................................................................. 40
3.5 Driveshields......................................................................................................................................... 42
3.5.1 Opening Driveshields .................................................................................................................... 42
3.5.2 Closing Driveshields...................................................................................................................... 44
3.6 Cutterbar Curtain ................................................................................................................................. 45
3.6.1 Opening Cutterbar Curtain............................................................................................................. 45
3.6.2 Closing Cutterbar Curtain .............................................................................................................. 46
3.7 Header Settings.................................................................................................................................... 47
3.7.1 Cutting Height ............................................................................................................................. 47
Adjusting Skid Shoe Height ........................................................................................................... 48
Adjusting Gauge Roller Height....................................................................................................... 49
3.7.2 Adjusting Cutterbar Angle.............................................................................................................. 52
TABLE OF CONTENTS

215026 viii Revision A
3.7.3 Header Float ............................................................................................................................... 52
3.7.4 Ground Speed ............................................................................................................................. 53
3.8 Conditioner ......................................................................................................................................... 54
3.8.1 Roll Gap ..................................................................................................................................... 54
Adjusting Roll Gap –Steel Rolls ..................................................................................................... 54
Adjusting Roll Gap –Polyurethane Rolls.......................................................................................... 55
3.8.2 Roll Tension ................................................................................................................................ 56
Adjusting Roll Tension ................................................................................................................. 56
3.8.3 Roll Timing.................................................................................................................................. 57
Checking Roll Timing ................................................................................................................... 57
Adjusting Roll Timing................................................................................................................... 57
3.8.4 Forming Shields –Roll Conditioner.................................................................................................. 61
Positioning Forming Shield Side Deflectors –Roll Conditioner............................................................. 61
Positioning Rear Baffle –Roll Conditioner ....................................................................................... 62
3.9 Cutterbar Deflectors ............................................................................................................................. 65
3.9.1 Removing Cutterbar Deflectors....................................................................................................... 65
3.9.2 Installing Cutterbar Deflectors ........................................................................................................ 66
3.10 Haying Tips ........................................................................................................................................ 67
3.10.1 Curing ...................................................................................................................................... 67
3.10.2 Topsoil Moisture ........................................................................................................................ 67
3.10.3 Weather and Topography ............................................................................................................ 67
3.10.4 Windrow Characteristics.............................................................................................................. 68
3.10.5 Driving on Windrow.................................................................................................................... 68
3.10.6 Using Chemical Drying Agents ...................................................................................................... 68
3.11 Transporting the Header ...................................................................................................................... 69
Chapter 4: Maintenance and Servicing.................................................................................................... 71
4.1 Daily Start-Up Check ............................................................................................................................. 71
4.2 Preparing Machine for Servicing.............................................................................................................. 73
4.3 Recommended Safety Procedures ........................................................................................................... 74
4.4 Maintenance Requirements ................................................................................................................... 76
4.4.1 Maintenance Schedule/Record....................................................................................................... 76
4.4.2 Break-In Inspections ..................................................................................................................... 78
4.4.3 Preseason Servicing...................................................................................................................... 78
4.4.4 End-of-Season Servicing ................................................................................................................ 79
4.5 Lubrication .......................................................................................................................................... 80
4.5.1 Greasing Procedure ...................................................................................................................... 80
4.5.2 Lubrication Locations.................................................................................................................... 81
4.6 Cutterbar System.................................................................................................................................. 83
4.6.1 Lubricating Cutterbar.................................................................................................................... 83
Checking and Adding Lubricant in Cutterbar .................................................................................... 83
Draining the Cutterbar................................................................................................................. 86
Filling Cutterbar with Lubricant ..................................................................................................... 87
4.6.2 Cutterbar Discs ............................................................................................................................ 88
Inspecting Cutterbar Discs ............................................................................................................ 89
TABLE OF CONTENTS

215026 ix Revision A
Removing Cutterbar Discs ............................................................................................................ 90
Installing Cutterbar Discs.............................................................................................................. 92
4.6.3 Cutterbar Spindles........................................................................................................................ 93
Removing Cutterbar Spindles ........................................................................................................ 94
Installing Cutterbar Spindles ......................................................................................................... 96
4.6.4 Disc Blades ............................................................................................................................... 101
Inspecting Disc Blades ............................................................................................................... 102
Inspecting Disc Blade Hardware .................................................................................................. 103
Removing Disc Blades................................................................................................................ 105
Installing Disc Blades ................................................................................................................. 107
4.6.5 Accelerators.............................................................................................................................. 108
Inspecting Accelerators.............................................................................................................. 108
Removing Accelerators .............................................................................................................. 109
Installing Accelerators ............................................................................................................... 111
4.6.6 Rock Guards.............................................................................................................................. 112
Inspecting Rock Guards.............................................................................................................. 112
Removing Rock Guards .............................................................................................................. 113
Installing Rock Guards ............................................................................................................... 114
4.6.7 Drums...................................................................................................................................... 114
Inspecting Drums...................................................................................................................... 115
Removing Suspended Drums ...................................................................................................... 117
Installing Suspended Drums........................................................................................................ 119
Replacing Left Suspended Drum Drive Belt .................................................................................... 120
Replacing Right Suspended Drum Drive Belt .................................................................................. 124
Removing Left Driven Drum and Driveline..................................................................................... 126
Installing Left Driven Drum and Driveline ...................................................................................... 129
Removing Right Driven Drum and Driveline ................................................................................... 132
Installing Right Driven Drum and Driveline .................................................................................... 135
4.6.8 Cutterbar Spindle Shear Pin ......................................................................................................... 138
Removing Cutterbar Spindle Shear Pin.......................................................................................... 139
Installing Cutterbar Spindle Shear Pin ........................................................................................... 143
4.6.9 Reconfiguring Cutterbar Crop Stream ............................................................................................ 146
Changing R216 SP Cutterbar Crop Stream Configuration .................................................................. 147
4.7 Conditioner Roll Timing Gearbox .......................................................................................................... 149
4.7.1 Checking and Changing Conditioner Roll Timing Gearbox Oil.............................................................. 149
4.8 Header Drive Gearbox ......................................................................................................................... 152
4.8.1 Checking Oil in Header Drive Gearbox............................................................................................ 152
4.8.2 Changing Oil in Header Drive Gearbox ........................................................................................... 154
4.9 Cutterbar Curtain ............................................................................................................................... 155
4.9.1 Inspecting Cutterbar Curtain ........................................................................................................ 155
4.9.2 Removing Cutterbar Curtain......................................................................................................... 156
4.9.3 Installing Cutterbar Curtain.......................................................................................................... 157
4.10 Conditioner ..................................................................................................................................... 158
4.10.1 Inspecting Conditioner .............................................................................................................. 158
Conditioner Drive Belt ............................................................................................................... 160
4.11 Replacing Driveshields ....................................................................................................................... 165
4.11.1 Removing Driveshields .............................................................................................................. 165
4.11.2 Installing Driveshields................................................................................................................ 166
TABLE OF CONTENTS

215026 xRevision A
4.12 Electrical System............................................................................................................................... 168
4.12.1 Maintaining Electrical System ..................................................................................................... 168
4.12.2 Replacing Amber Hazard/Signal Light ........................................................................................... 168
4.12.3 Replacing Header Disc Speed Sensor............................................................................................ 169
4.13 Hydraulics ....................................................................................................................................... 170
4.13.1 Checking Hydraulic Hoses and Lines............................................................................................. 170
Chapter 5: Options and Attachments .................................................................................................... 171
5.1 Cutterbar Deflectors –MD #B6847 ........................................................................................................ 171
5.2 Double Windrow Attachment –MD #C2070 ............................................................................................ 172
5.3 Disc Feed Plate Kit –MD #B6669........................................................................................................... 173
5.4 Electric Remote Baffle Kit –MD #B6664 ................................................................................................. 174
5.5 Adjustable Gauge Roller Kit –MD #B6855............................................................................................... 175
5.6 Polyurethane Intermeshing Roller –MD #B6661 ...................................................................................... 176
5.7 Steel Intermeshing Roller –MD #B6662.................................................................................................. 177
5.8 Adjustable Skid Shoes Kit –MD #B6848.................................................................................................. 178
5.9 Tall Crop Divider Kit –MD #B6808 ......................................................................................................... 179
Chapter 6: Troubleshooting.................................................................................................................... 181
6.1 Performance Problems ........................................................................................................................ 181
6.2 Mechanical Problems .......................................................................................................................... 184
Chapter 7: Reference .............................................................................................................................. 187
7.1 Torque Specifications .......................................................................................................................... 187
7.1.1 Metric Bolt Specifications ............................................................................................................ 187
7.1.2 Metric Bolt Specifications Bolting into Cast Aluminum ...................................................................... 189
7.1.3 O-Ring Boss Hydraulic Fittings –Adjustable .................................................................................... 190
7.1.4 O-Ring Boss Hydraulic Fittings –Non-Adjustable.............................................................................. 192
7.1.5 O-Ring Face Seal Hydraulic Fittings................................................................................................ 193
7.1.6 Tapered Pipe Thread Fittings........................................................................................................ 194
7.2 Conversion Chart................................................................................................................................ 195
Index........................................................................................................................................................ 197
Recommended Lubricants...................................................................................................................... 201
TABLE OF CONTENTS

215026 1Revision A
Chapter 1: Safety
1.1 Safety Alert Symbols
1000915
Figure 1.1: Safety Symbol
This safety alert symbol indicates important safety messages in
this manual and on safety signs on the machine.
This symbol means:
•ATTENTION!
•BECOME ALERT!
•YOUR SAFETY IS INVOLVED!
Carefully read and follow the safety message accompanying this
symbol.
Why is safety important to you?
•Accidents disable and kill
•Accidents cost
•Accidents can be avoided

215026 2Revision A
1.2 Signal Words
Three signal words, DANGER,WARNING, and CAUTION, are used to alert you to hazardous situations. Two signal words,
IMPORTANT and NOTE, identify non-safety related information. Signal words are selected using the following guidelines:
DANGER
Indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury.
WARNING
Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury. It may also be
used to alert against unsafe practices.
CAUTION
Indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury. It may be used
to alert against unsafe practices.
IMPORTANT:
Indicates a situation that, if not avoided, could result in a malfunction or damage to the machine.
NOTE:
Provides additional information or advice.
SAFETY

215026 3Revision A
1.3 General Safety
1000004
Figure 1.2: Safety Equipment
CAUTION
The following general farm safety precautions should be part of
your operating procedure for all types of machinery.
Protect yourself when assembling, operating, and servicing
machinery, wear all protective clothing and personal safety
devices that could be necessary for the job at hand. Do NOT
take chances. You may need the following:
•Hard hat
•Protective footwear with slip-resistant soles
•Protective glasses or goggles
•Heavy gloves
•Wet weather gear
•Respirator or filter mask
1000005
Figure 1.3: Safety Equipment
•Be aware that exposure to loud noises can cause hearing
impairment or loss. Wear suitable hearing protection devices
such as earmuffs or earplugs to help protect against loud
noises.
1010391
Figure 1.4: Safety Equipment
•Provide a first aid kit in case of emergencies.
•Keep a properly maintained fire extinguisher on the machine.
Be familiar with its proper use.
•Keep young children away from machinery at all times.
•Be aware that accidents often happen when the Operator is
tired or in a hurry. Take time to consider safest way. NEVER
ignore warning signs of fatigue.
SAFETY

215026 4Revision A
1000007
Figure 1.5: Safety around Equipment
•Wear close-fitting clothing and cover long hair. NEVER wear
dangling items such as scarves or bracelets.
•Keep all shields in place. NEVER alter or remove safety
equipment. Make sure driveline guards can rotate
independently of shaft and can telescope freely.
•Use only service and repair parts made or approved by
equipment manufacturer. Substituted parts may not meet
strength, design, or safety requirements.
1000008
Figure 1.6: Safety around Equipment
•Keep hands, feet, clothing, and hair away from moving parts.
NEVER attempt to clear obstructions or objects from a
machine while the engine is running.
•Do NOT modify the machine. Unauthorized modifications
may impair machine function and/or safety. It may also
shorten the machine’s life.
•To avoid injury or death from unexpected startup of the
machine, ALWAYS stop the engine and remove the key from
the ignition before leaving the operator’s seat for any reason.
1000009
Figure 1.7: Safety around Equipment
•Keep service area clean and dry. Wet and/or oily floors are
slippery. Wet spots can be dangerous when working with
electrical equipment. Be sure all electrical outlets and tools
are properly grounded.
•Keep work area well lit.
•Keep machinery clean. Straw and chaff on a hot engine are
fire hazards. Do NOT allow oil or grease to accumulate on
service platforms, ladders, or controls. Clean machines before
storage.
•NEVER use gasoline, naphtha, or any volatile material for
cleaning purposes. These materials may be toxic and/or
flammable.
•When storing machinery, cover sharp or extending
components to prevent injury from accidental contact.
SAFETY

215026 5Revision A
1.4 Maintenance Safety
1000009
Figure 1.8: Safety around Equipment
To ensure your safety while maintaining machine:
•Review the operator’s manual and all safety items before
operation and/or maintenance of the machine.
•Place all controls in Neutral, stop the engine, set the park
brake, remove the ignition key, and wait for all moving parts
to stop before servicing, adjusting, and/or repairing.
•Follow good shop practices:
–Keep service areas clean and dry
–Be sure electrical outlets and tools are properly grounded
–Keep work area well lit
1008958
Figure 1.9: Equipment NOT Safe for Children
•Relieve pressure from hydraulic circuits before servicing
and/or disconnecting the machine.
•Make sure all components are tight and that steel lines,
hoses, and couplings are in good condition before applying
pressure to hydraulic systems.
•Keep hands, feet, clothing, and hair away from all moving
and/or rotating parts.
•Clear the area of bystanders, especially children, when
carrying out any maintenance, repairs, or adjustments.
•Install transport lock or place safety stands under the frame
before working under the machine.
•If more than one person is servicing the machine at the
same time, be aware that rotating a driveline or other
mechanically-driven component by hand (for example,
accessing a lubricant fitting) will cause drive components in
other areas (belts, pulleys, and knives) to move. Stay clear of
driven components at all times.
1000004
Figure 1.10: Safety Equipment
•Wear protective gear when working on the machine.
•Wear heavy gloves when working on knife components.
SAFETY

215026 6Revision A
1.5 Hydraulic Safety
1001205
Figure 1.11: Testing for Hydraulic Leaks
•Always place all hydraulic controls in Neutral before leaving
the operator’s seat.
•Make sure that all components in the hydraulic system are
kept clean and in good condition.
•Replace any worn, cut, abraded, flattened, or crimped hoses
and steel lines.
•Do NOT attempt any makeshift repairs to hydraulic lines,
fittings, or hoses by using tapes, clamps, cements, or welding.
The hydraulic system operates under extremely high-
pressure. Makeshift repairs will fail suddenly and create
hazardous and unsafe conditions.
1001207
Figure 1.12: Hydraulic Pressure Hazard
•Wear proper hand and eye protection when searching for
high-pressure hydraulic leaks. Use a piece of cardboard as a
backstop instead of hands to isolate and identify a leak.
•If injured by a concentrated high-pressure stream of
hydraulic fluid, seek medical attention immediately. Serious
infection or toxic reaction can develop from hydraulic fluid
piercing the skin.
1000013
Figure 1.13: Safety around Equipment
•Make sure all components are tight and steel lines, hoses,
and couplings are in good condition before applying pressure
to a hydraulic system.
SAFETY

215026 7Revision A
1.6 Welding Precaution
Welding should never be attempted on the header while it is connected to a windrower.
WARNING
Severe damage to sensitive, expensive electronics can result from welding on the header while it is connected to the
windrower. It can be impossible to know what effect high current could have with regard to future malfunctions or
shorter lifespan. It is very important that welding on the header is not attempted while the header is connected to the
windrower.
If an Operator needs to do any welding on the header, it should first be disconnected and removed from the windrower.
If it is unfeasible to disconnect the header from the windrower before attempting welding, contact your MacDon Dealer for
welding precautions detailing all electrical components that must be disconnected first for safe welding.
SAFETY

215026 8Revision A
1.7 Safety Signs
1000694
Figure 1.14: Operator’s Manual Decal
•Keep safety signs clean and legible at all times.
•Replace safety signs that are missing or illegible.
•If the original part on which a safety sign was installed is
replaced, be sure the repair part displays the current
safety sign.
•Replacement safety signs are available from Dealer Parts
Department.
1.7.1 Installing Safety Decals
1. Clean and dry the installation area.
2. Decide exactly where you are going to place the decal.
3. Remove the smaller portion of the split backing paper.
4. Place the decal in position and slowly peel back the remaining paper, smoothing the decal as it is applied.
5. Prick small air pockets with a pin and smooth out.
SAFETY